Replaceable Adapter For Use With Vehicular Battery Charging System

ABSTRACT

An energy transfer system includes an adapter having a power terminal port with a plurality of power terminals and an intermediate adapter terminal port with a plurality of intermediate adapter terminals. Each of the plurality of intermediate adapter terminals is in direct electrical communication with one of the plurality of adapter terminals. The energy transfer system also includes an intermediate complementary port that is configured to mate with the intermediate adapter terminal port to establish electrical communication between the plurality of intermediate adapter terminals and a plurality of complementary intermediate terminals. The adapter terminal port is configured not to mate with the intermediate terminal port and not to mate with the intermediate complementary terminal port.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.61/786,792, filed Mar. 15, 2013, the disclosure of which is incorporatedherein by reference.

BACKGROUND OF THE INVENTION

This invention relates in general to battery charging systems, such asare used to connect a battery of an electric vehicle to an exteriorelectric power source. In particular, this invention relates to animproved structure for such a battery charging system, wherein thestructure includes an adapter for charging the electrical vehicle from aconvention 110-volt outlet.

Electric vehicles are typically provided with one or more rechargeablebatteries. In some vehicles, the rechargeable batteries may be chargedby plugging in to an external power source, such as a conventionalelectrical outlet. Such charging of the vehicle batteries may occurfrequently, and plugging in a vehicle to charge once a day is notunusual. Each time the vehicle battery is charged, a charging cord of abattery charging system provided on the vehicle is connected to anelectrical outlet assembly, then is subsequently removed therefrom inorder to stop charging or to operate the vehicle. As a result, thephysical acts of both plugging in the charging cord to the electricaloutlet and subsequently removing same can occur frequently. Therefore,the charging cord of the conventional battery charging system issubjected to undesirable mechanical fatigue and potential failure.Failure in the charging cord can make it difficult or impossible torecharge the rechargeable batteries without first repairing the chargingcord. It would be desirable to provide an improved structure for such abattery charging system that avoids this potential problem.

SUMMARY OF THE INVENTION

This invention relates to an energy transfer system. The energy transfersystem includes an adapter having a power terminal port. The powerterminal port includes a plurality of power terminals. The energytransfer system includes an intermediate adapter terminal port. Theintermediate adapter terminal port includes a plurality of intermediateadapter terminals. Each of the plurality of intermediate adapterterminals is in direct electrical communication with one of theplurality of adapter terminals. The energy transfer system includes anintermediate complementary port. The intermediate complementary port isconfigured to mate with the intermediate adapter terminal port toestablish electrical communication between the plurality of intermediateadapter terminals and a plurality of complementary intermediateterminals. The adapter terminal port is configured not to mate with theintermediate terminal port. The adapter terminal port is configured notto mate with the intermediate complementary terminal port.

This invention also relates to an adapter for an energy transfer system.The adapter includes a power terminal port. The power terminal portincludes a plurality of power terminals. The adapter includes anintermediate adapter terminal port. The intermediate adapter terminalport includes a plurality of intermediate adapter terminals. Each of theplurality of intermediate adapter terminals is in direct electricalcommunication with one of the plurality of power terminals. The powerterminal port is configured to mate with a complementary power terminalport. The intermediate adapter terminal port is configured not to matewith the complementary power terminal port.

Various aspects of this invention will become apparent to those skilledin the art from the following detailed description of the preferredembodiment, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an energy transfer system having areplaceable adapter.

FIG. 2 is a perspective view, from the front, of an end portion of acharging cable for the battery charging system shown illustrated in FIG.1.

FIG. 3 is an exploded perspective view of the end portion of thecharging cable illustrated in FIG. 2.

FIG. 4 is a perspective view, from behind, of the replaceable adaptershown in FIG. 1.

FIG. 5 is an exploded perspective view of the end portion of thereplaceable adapter of FIG. 4.

FIG. 6 is a perspective view, from behind, of the end portion of thecharging cable attached to the replaceable adapter.

FIG. 7 is a schematic view of an alternative energy transfer systemhaving an alternative replaceable adapter that includes a splice box.

FIG. 8 is an exploded view of the splice box of FIG. 7.

FIG. 9 is a close-up view of an electric terminal from the splice box ofFIG. 8.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings, there is illustrated in FIG. 1 aschematic view of an energy transfer system, indicated generally at 10.The illustrated energy transfer system 10 is configured to provideelectrical power from a power source 12 to a battery 14 on an electricvehicle, shown schematically at 15. However, it should be appreciatedthat this is only one embodiment, and the energy transfer system 10 maybe used in other electrical energy transfer applications, if desired,and is not limited to recharging batteries, nor is it limited totransferring power to the electrical vehicle 15.

The illustrated energy transfer system 10 includes a stationary-side,indicated generally at 16, and a vehicle-side, indicated generally at18. The stationary-side 16 includes the power source 12 and an outlet20. Power is supplied from the power source 12 to the outlet 18 by apower line 22. The illustrated outlet 20 is a conventional three-prongoutlet and the power source 12 is a conventional municipal power source.However, it should be appreciated that the power source 12 may be anydesired source of electrical power, such as a generator or batteries,and the outlet 20 may be any desired electrical connector, such as a twoprong outlet, a 220-volt connector, or a customized electricalconnection. The power line 22 is shown only schematically, but caninclude all wiring, breakers, and other components necessary to provideelectrical power from the power source 12 to the outlet 20.

The components of the vehicle-side 18 are configured to transfer powerfrom the outlet 20 to the battery 14. The vehicle-side 18 includes aplug 24 that is configured to engage the outlet 20. The illustrated plug24 is a conventional three-prong, but it should be appreciated that theplug 24 can be any desired type of connector that is compatible with theoutlet 20. The plug 24 is part of a charging cord assembly, indicatedgenerally at 26, that is connected to the battery 14. The charging cordassembly 26 is shown only schematically, but can include all wiring,breakers, and other components necessary to provide electrical powerfrom the power source 12 to the battery 14 and may include anycomponents of a vehicle charging system, indicated schematically at 28,that are adapted to receive and process the electrical current from thepower source 12 for charging the battery 14.

The charging cord assembly 26 includes a replaceable adapter, indicatedgenerally at 30. The replaceable adapter 30 is provided on the chargingcord assembly 26 in order to allow the portions of the charging cordassembly 26 that are expected to experience the most wear to be replacedrelatively easily. In normal use of the charging cord assembly 26, theplug 24 is inserted into the outlet 20 in order to transfer power fromthe power source 12 to the battery 14 to charge the battery 14. The plug24 includes a plurality of terminals 32, which areelectrically-conductive blades and which engage a plurality ofcomplementary terminals in the outlet 20, which are female terminals(not shown). The female terminals are biased against the blades 32 inorder to maintain electrical contact between the female terminals andthe blades 32. When it is no longer desired to charge the battery 14,the plug 24 is unplugged from the outlet 20, disengaging the femaleterminals and the blades 32. It should be appreciated that repeatedlyplugging and unplugging the plug 24 into the outlet 20 can result inwear to both the plug 24 and the outlet 20, and as a result it may benecessary to replace the plug 24 during the useful life of the chargingcord assembly 26. The replaceable adapter 30 allows the plug 24 to bereplaced without having to replace the entire charging cord assembly 26.It should be appreciated that the replaceable adapter 30 allows the plug24 to be replaced if it is damaged by any cause.

Referring now to FIG. 2, there is shown a perspective view, from thefront, of an adapter plug, indicated generally at 34. The adapter plug34 is located on the charging cord assembly 26. Referring to FIG. 3, aview similar to that of in FIG. 2 is shown, with a receptacle housing 42removed from the charging cord assembly 26. As shown, the charging cordassembly 26 includes an adapter end 36 where adapter blades 38 areconnected to charge wires 40. The illustrated charging cord assembly 26includes three charge wires 40 and three adapter blades 38, one hotlead, one neutral lead, and one ground lead. It should be appreciatedthat the charging cord assembly 26 may include a different number orconfiguration of charge wires 40 from that illustrated, if desired.Additionally, it should be appreciated that the adapter blades 38 may bereplaced with other desired electrical terminals, such as femaleterminals or barrel terminals. The adapter blades 38 are in electricalcommunication with the vehicle charging system 28 through the chargewires 40, and allow electric current to be supplied to the vehiclecharging system 28 to charge the battery 14. The adapter plug 34includes the receptacle housing 42. The receptacle housing 42 is aplastic piece that serves, in part, to hold the adapter blades 38. Asshown in FIG. 3, the receptacle housing 42 includes plurality of slots44 that the adapter blades 38 are press fit into in order to assemblethe adapter plug 34, as shown in FIG. 2. The adapter plug 34 includes anoptional shroud 46 that at least partially surrounds the assembledadapter blades 38. The shroud 46 serves in part to protect the adapterblades 38 from damage. The adapter plug 34 also includes an optionallatch 48, the operation of which will be described below. It should beappreciated that the illustrated adapter plug 34 is only one,non-limiting embodiment and the adapter plug 34 may be made of differentmaterials and may have a different structure from that illustrated, ifdesired.

Referring now to FIG. 4, there is shown a perspective view, from behind,of the replaceable adapter 30. FIG. 5 is a view similar to FIG. 4,showing an exploded view of the replaceable adapter 30. The replaceableadapter 30 includes an adapter cord 50 that connects the plug 24 to anadapter outlet, indicated generally at 52. The adapter cord 50 may be ofany desired length. Further, the adapter outlet 52 may be connecteddirectly to the plug 24, if desired, omitting the adapter cord 50entirely. As shown in FIG. 5, the adapter outlet 52 includes threeadapter outlet terminals 54 that are connected to adapter wires 56located in the adapter cord 50. The illustrated adapter cord 50 includesthree adapter wires 56, one hot lead, one neutral lead, and one groundlead. It should be appreciated that the adapter cord 50 may include adifferent number or configuration of adapter wires 56 from thatillustrated, if desired. Additionally, it should be appreciated that theadapter outlet terminals 54 may be replaced with other desiredelectrical terminals, such as male blade terminals or pin terminals. Theadapter wires 56 are also attached to the blades 32 on the plug 24, inorder to provide electrical communication between the plug 24 and theadapter outlet 52. Each of the adapter outlet terminals 54 is in directelectrical communication with one of the blades 32. That is, a voltagedifference between the hot lead and the neutral lead at the plug 24 willbe the same as the voltage difference between the hot lead and theneutral lead at the adapter outlet 52, excepting for losses in theadapter cord 50.

The adapter outlet 52 includes an adapter outlet housing 58. The adapteroutlet housing 58 is a plastic piece that serves, in part, to hold theadapter outlet terminals 54. As shown in FIG. 5, the adapter outlethousing 58 includes plurality of adapter slots 60 that extendtherethrough. The adapter outlet terminals 54 are supported within theadapter slots 60. The adapter outlet 52 also includes a cord support 62.The cord support 62 is snap fit onto the adapter outlet housing 58 (asshown in FIG. 4) in order to help maintain the adapter cord 50 in theproper position relative to the adapter outlet housing 58 and to helpmaintain the adapter outlet terminals 54 in the proper position withinthe adapter slots 60.

As shown in FIG. 6, the adapter plug 34 and the adapter outlet 52 may bemated. This electrically connects the replaceable adapter 30 to thevehicle charging system 28. The shroud 46 on the receptacle housing 42partially surrounds the adapter outlet housing 58 and the adapter blades38 are inserted into the adapter slots 60 to engage the respectiveadapter outlet terminals 54. It should be appreciated that the adapterplug terminals 54 on the adapter outlet 52 are compatible with theadapter blades 38 on the adapter plug 34. As seen in FIG. 4 and FIG. 5,the adapter outlet 52 includes an optional O-ring 64 that is placed in acircumferential groove 66 on the adapter outlet housing 58. When theadapter plug 34 and the adapter outlet 52 are mated, the O-ring 64 islocated between the adapter outlet housing 58 and the shroud 46, andprovides a seal to help prevent debris from coming into contact with theadapter blades 38 and the adapter plug terminals 54. Additionally, theadapter outlet 52 includes an optional post 68. The post 68 is engagedby the latch 48 on the adapter plug 34 in order to maintain the positionof the adapter plug 34 relative to the adapter outlet 52. The adapterplug 34 includes an optional guide 70, which is a groove in the adapteroutlet housing 58. The adapter outlet 52 includes a correspondingprojection (not shown) on the shroud 46. The guide 70 serves to limitthe positions in which an operator may attempt to mate the adapter plug34 and the adapter outlet 52, in order to assist in proper alignment ofthe adapter plug 34 and to help prevent damage to the adapter blades 38.

The adapter plug 34 and the adapter outlet 52 provide the charging cordwith an intermediate outlet and plug between the battery 14 and the plug24. That is, the vehicle charging system 28 includes a plug 24 that isconfigured to be connected to a power source 14 by mating with theoutlet 20, and it also includes the adapter plug 34 that is locatedbetween the plug 24 and the battery 14. Additionally, in the illustratedembodiment, the adapter plug 34 is not able to be mated with the outlet20. As can be seen in reference to FIGS. 1 and 2, the shroud 46 extendsforward of the adapter blades 38, which will help prevent the adapterblades 38 from being inserted into the outlet 20. Additionally, theconfiguration of the adapter blades 38 is different from configurationof the terminals 32 and the adapter blades 38 are not compatible withthe outlet 20, which also helps prevent the adapter blades 38 from beinginserted into the outlet 20. This incompatibility between the adapterplug 34 and the outlet 20 is an optional feature that is advantageous inthat it prevents the operator from mating the adapter plug 34 directlywith the outlet 20 either intentionally or accidentally. It should beappreciated that while the illustrated embodiment has the adapter outlet52 as part of the replaceable adapter 30 and wired directly to the plug24, this is not necessary. If desired, the adapter plug 34 may be partof the replaceable adapter 30.

In use, the replaceable adapter 30 is connected to the charging cordassembly 26 and the operator mates the plug 24 with the outlet 20 tocharge the battery 14, and removes the plug 24 from the outlet 20 tooperate the electric vehicle 15. When it becomes necessary to replacethe plug 24 due to wear or damage, the operator disengages the adapterplug 34 from the adapter outlet 52 and replaces the replaceable adapter30 with a new replaceable adapter (not shown). The original replaceableadapter 30 may be dealt with by being disposed of or being sent to themanufacturer for repair, for example.

The illustrated embodiment shows the replaceable adapter 30 as part ofthe vehicle charging system 28. However, it should be appreciated thatthe replaceable adapter may be included alternatively or additionally aspart of the stationary-side 16, if desired.

It should be appreciated that the previously-described embodiment isonly one, non-limiting example. In other embodiments, the plug 24 may beany desired power terminal port, such as a conventional two-prong plug,a 220-volt plug, an SAE J1772 connector, or a conventional three-plugoutlet, for example. Further, the outlet 20 may be any complementaryterminal port that is configured to mate with the adapter terminal port.Further, the adapter outlet 52 may be any desired intermediate adapterterminal port, and the adapter plug 34 may be any intermediatecomplementary terminal port that is configured to mate with theintermediate terminal port. So, for example, the replaceable adapter mayhave two male ends, or two female ends. Further, the optional feature ofpreventing the operator from not using the replaceable adapter 30 may beprovided by configuring the intermediate complementary terminal port sothat it cannot mate with the first complementary terminal port.

Referring now to FIG. 7, there is shown an alternative energy transfersystem, indicated generally at 110. The alternative energy transfersystem 110 includes many features in common with the previouslydescribed energy transfer system 10. Those features that are common areidentified by the same element number, incremented by 100, and will notbe described in detail. The alternative energy transfer system alsoincludes a splice box, indicated generally at 172, that may be used toconnect a replaceable adapter 130 to a charging cord 126. Additionally,it should be appreciated that the splice box 172 may also be used in anyother application.

Referring to FIG. 8, an exploded view of the splice box 172 is shown.The illustrated splice box 172 includes a splice housing 174, a faceseal 176, a terminal cover 178, a plurality of splice blades 180, and asplice cover 182. The splice box 172 may have different components fromthose illustrated, if desired. The splice housing 174 may be molded froma polycarbonate, or may be made of any other desired material. Theillustrated splice housing 174 includes openings 182 to allow thecharging cord 126 and an adapter cord 150 to be inserted into the splicehousing 174.

The charging cord 126 includes a splice end 136 where adapter terminals138 are connected to charge wires 140. The illustrated charging cord 126includes three charge wires 140 and three charge terminals 138, one hotlead, one neutral lead, and one ground lead. It should be appreciatedthat the charging cord 126 may include a different number orconfiguration of charge wires 140 from that illustrated, if desired.Additionally, it should be appreciated that the charge terminals 138 maybe replaced with other desired electrical connectors. The adapter cord150 includes three adapter terminals 154 that are connected to adapterwires 156 located in the adapter cord 150. The illustrated adapter cord150 includes three adapter wires 156 and three adapter terminals 154,one hot lead, one neutral lead, and one ground lead. It should beappreciated that the adapter cord 150 may include a different number orconfiguration of adapter wires 156 from that illustrated, if desired.Additionally, it should be appreciated that the adapter terminals 154may be replaced with other desired electrical connectors.

The splice housing 174 may include terminal mounts 184. The illustratedterminal mounts 184 are channels molded into the body of the splicehousing 174. However, the terminal mounts 184 may be made using otherdesired methods. The illustrated splice housing 174 includes threeterminal mounts 184, but may include any desired number of terminalmounts. Each terminal mount 184 may be configured to retain one chargeterminal 138 and one adapter terminal 154. One of the terminal mounts184 retains the charge terminal 138 hot lead and the adapter terminal154 hot lead as a corresponding pair of terminals. The second terminalmount 184 retains the charge terminal 138 neutral lead and the adapterterminal 154 neutral lead as a corresponding pair of terminals. Thethird terminal mount 184 retains the charge terminal 138 ground lead andthe adapter terminal 154 ground lead as a corresponding pair ofterminals. Each of the corresponding terminals 138 and 154 may beretained by the terminal mount 184 so that there is a terminal gap 186between them and they and are not in electrical communication with eachother.

The terminal cover 178 may be molded from a polycarbonate, or may bemade of any other desired material. The terminal cover 178 may beattached to the splice housing 174 by screws 187 or by any desiredfastener or method. The terminal cover 178 may cover the chargeterminals 138 and the adapter terminals 154. The terminal cover 178 maydefine a plurality of cover openings 188 that pass therethrough. Theillustrated terminal cover 178 defines three cover openings 188, andwhen the terminal cover 178 is attached to the splice housing 174 eachcover opening 188 is adjacent a terminal gap 186. The terminal cover 178may include any desired number of cover openings 188. The purpose of thecover openings 188 will be described below.

The splice cover 180 may be molded from a polycarbonate, or may be madeof any other desired material. The splice cover 180 may be attached tothe splice housing 174 by screws 187 or by any desired fastener ormethod. The splice cover 180 may include a plurality of blade mounts190. The illustrated blade mounts 190 are molded as part of the splicecover 180, but the blade mounts 190 may be made by any desired method.The illustrated splice cover 180 includes three blade mounts 190, andeach blade mount 190 retains a splice blade 192. When the splice cover180 is attached to the splice housing 174, each splice blade 192 extendsthrough one of the covering openings 188 in the terminal cover and intothe terminal gap 186 adjacent to the respective covering opening 188.The each of the splice blades 188 may engage one charge terminal 138 andone adapter terminal 154 of a corresponding pair of terminals. Thesplice blades 188 then provide electric communication between the chargeterminal 138 hot lead and the adapter terminal 154 hot lead, between thecharge terminal 138 neutral lead and the adapter terminal 154 neutrallead, and between the charge terminal 138 ground lead and the adapterterminal 154 ground lead.

The face seal 176 may be made of synthetic rubber or any other desiredmaterial. The face seal 176 may be located between the splice housing174 and the splice cover 180 in order to seal the splice box 172 toprotect the terminals 138 and 154 from water and other environmentalfactors. Cord seals 194 may be provided on the charging cord 126 and theadapter cord 150 to seal the respective openings 182 in order to sealthe splice box 172 to protect the terminals 138 and 154 from water andother environmental factors.

Referring to FIG. 9, a detail view of one of the charge terminal 138 isshown. Each of the charge terminals 138 and the adapter terminals 154may have the same design, or may have different designs if desired. Thecharge terminal 138 is a female terminal that includes extended contactarms 194. The charge terminal 138 may be any other desired type ofterminal. When the splice box 172 is assembled, the splice blade 192 isinserted between and is engaged by the contract arms 194. As previouslydescribed, each splice blade 192 will be inserted between the contactarms 194 of one charge terminal 138 and one adapter terminal 154, inorder to establish electrical communication between the terminals 138and 154.

In the illustrated embodiment, the charge terminal 138 is oriented sothat the splice blade 192 engages from the charge terminal 138 from theside. However, the charge terminal 138 may be oriented so that thesplice blade 192 engages it from any desired orientation. The chargeterminal 138 may include guides 196 that extend from the contact arms194. The guides 194 define a funnel that helps to position the spliceblade 192 between the contact arms 194 when the splice box 172 isassembled. It should be appreciated that when the splice cover 180 isremoved from the splice box 172, the splice blades 192 will be removedfrom the respective terminal gaps 186, which may end electricalcommunication between the charge terminals 138 and the adapter terminals154.

The principle and mode of operation of this invention have beenexplained and illustrated in its preferred embodiment. However, it mustbe understood that this invention may be practiced otherwise than asspecifically explained and illustrated without departing from its spiritor scope.

What is claimed is:
 1. An energy transfer system comprising: an adapterhaving a power terminal port including a plurality of power terminals,and an intermediate adapter terminal port including a plurality ofintermediate adapter terminals, wherein each of the plurality ofintermediate adapter terminals is in direct electrical communicationwith one of the plurality of adapter terminals; and an intermediatecomplementary port that is configured to mate with the intermediateadapter terminal port to establish electrical communication between theplurality of intermediate adapter terminals and a plurality ofcomplementary intermediate terminals; wherein the adapter terminal portis configured not to mate with the intermediate terminal port and not tomate with the intermediate complementary terminal port.
 2. The energytransfer system of claim 1, wherein the power terminal port is a maleelectrical connector.
 3. The energy transfer system of claim 2, whereinthe intermediate adapter terminal port is a female electrical connector.4. The energy transfer system of claim 1, wherein the plurality ofterminals is arranged in a different configuration than the plurality ofsecond complementary terminals.
 5. The energy transfer system of claim4, wherein the intermediate complementary terminal port includes ashroud that at least partially surrounds the plurality of secondcomplementary terminals.
 6. The energy transfer system of claim 4,wherein the intermediate complementary port is in electricalcommunication with a vehicle charging system.
 7. The energy transfersystem of claim 1, wherein the intermediate complementary terminal portincludes a shroud that at least partially surrounds the plurality ofsecond complementary terminals.
 8. The energy transfer system of claim1, wherein the power terminal port is configured to mate with aconventional electrical outlet.
 9. The energy transfer system of claim8, wherein the intermediate complementary port is in electricalcommunication with a vehicle charging system.
 10. The energy transfersystem of claim 9, wherein vehicle charging system is configured tocharge a battery on a vehicle.
 11. An adapter for an energy transfersystem, the adapter comprising: a power terminal port including aplurality of power terminals; and an intermediate adapter terminal portincluding a plurality of intermediate adapter terminals, wherein each ofthe plurality of intermediate adapter terminals is in direct electricalcommunication with one of the plurality of power terminals; wherein thepower terminal port is configured to mate with a complementary powerterminal port, and the intermediate adapter terminal port is configurednot to mate with the complementary power terminal port.
 12. The adapterfor an energy transfer system of claim 11, wherein the power terminalport is a male electrical connector.
 13. The adapter for an energytransfer system of claim 12, wherein the intermediate adapter terminalport is a female electrical connector.
 14. An adapter for an energytransfer system, the adapter comprising: a power terminal port includinga plurality of power terminals; and an intermediate adapter terminalport including a plurality of intermediate adapter terminals, whereineach of the plurality of intermediate adapter terminals is in directelectrical communication with one of the plurality of power terminals;wherein the power terminal port is configured to mate with acomplementary power terminal port, and the intermediate adapter terminalport is configured not to mate with the complementary power terminalport.